Heating, Ventilation and Air Conditioning: Removal & Installation Honda Insight ZE2

Receiver/Dryer Desiccant Replacement

Note. Install the receiver/dryer as quickly as possible to prevent the system from absorbing moisture from the air.

Scheme 91

1. Remove the A/C condenser (see «A/C COMPRESSOR RELIEF VALVE REPLACEMENT»(ref-360275-S38425931112010042800000) ).
2. Remove the cap (A) from the bottom of the A/C condenser. Remove the O-ring (B) and the desiccant (C).
3. Install the receiver/dryer in the reverse order of removal, and note these items

1. Replace the O-rings with new ones, and apply a thin coat of refrigerant oil (SP-10) before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.
2. Install the cap to the specified torque. It is made of resin and can be easily stripped.

A/C Compressor Replacement

Note. Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure.

Scheme 92

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1. If the A/C compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2. Recover the refrigerant with a recovery/recycling/charging station (see «RECEIVER/DRYER DESICCANT REPLACEMENT»(ref-360275-S27565743102010042800000) ).
3. Raise the vehicle on the lift.
4. Remove the splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-360308-S41260454582010042800000) ).
5. Remove the drive belt (see «DRIVE BELT INSPECTION»(ref-360270-S17077343672010042800000) ).
6. Remove the compressor clutch connector (A) from the condenser fan shroud, then disconnect the connector. Remove the bolts, then disconnect the suction line (B) and the discharge line (C) from the compressor, and remove the O-rings (D). Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Remove the mounting bolts, and remove the A/C compressor from underneath the vehicle. Be careful not to damage the radiator fins when removing the A/C compressor. Do not drop the A/C compressor.
8. Install the compressor in the reverse order of removal, and note these items: Inspect the A/C lines for any signs of contamination. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Use refrigerant oil (SP-10) for HFC-134a SANDEN spiral type A/C compressor only. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Charge the system (see «SYSTEM CHARGING»(ref-360275-S23440977812010042800000) ).
9. Lower the vehicle on the lift.

A/C Compressor Relief Valve Replacement

Note. If the A/C compressor relief valve released refrigerant to the atmosphere, determine and correct the cause of the excessive system pressure, then replace the relief valve.

Scheme 94

1. Recover the refrigerant with a recovery/recycling/charging station (see «RECEIVER/DRYER DESICCANT REPLACEMENT»(ref-360275-S27565743102010042800000) ).
2. Remove the relief valve cover (A), the relief valve (B), and the O-ring (C). Plug the opening to keep foreign matter from entering the system and the A/C compressor oil from running out.
3. Clean the mating surfaces.
4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it.
5. Remove the plug installed in step 2, then install and tighten the relief valve.
6. Charge the system (see «SYSTEM CHARGING»(ref-360275-S23440977812010042800000) ).

Scheme 95

Scheme 96

1. Remove the bolt and the holder (A). Disconnect the field coil connector (B), then remove the thermal protector (C).
2. Replace the thermal protector (A) with a new one, and apply silicone sealant (B) to the bottom of the thermal protector. NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
3. Install the thermal protector in the reverse order of removal.

A/C Refrigerant Oil Replacement

Recommended PAG oil: SP-10

1. P/N 38897-P13-A01AH: 120 mL (4 fl-oz) It is important to have the correct amount of refrigerant oil in the A/C system to ensure proper lubrication of the A/C compressor. Too little oil damages the A/C compressor; too much oil reduces the cooling capacity of the system, and can produce high vent temperatures.

1. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
2. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
3. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately.

Add the recommended refrigerant oil in the amount listed if you replace any of the following parts.

A/C condenser

(including Dryer

Desiccant)..................25 mL (5/6 fl-oz)

Evaporator................35 mL (1 1/6 fl-oz)

Line or hose..............10 mL (1/3 fl-oz)

Receiver/Dryer

Desiccant...................10 mL (1/3 fl-oz)

Leakage repair..........25 mL (5/6 fl-oz)

A/C compressor........Since the oil separator is equipped inside the compressor for this vehicle, oil drainage is unnecessary at the time of compressor replacement.

Scheme 97

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1. Turn the ignition switch to LOCK (0).
2. Open the glove box. While holding the glove box, release the glove box stops on each side from the dashboard by pushing them in, then lower the glove box (see step 1).
3. Remove the lid (A) from the blower unit.
4. Pull out the dust and pollen filter (B).
5. Install the filter in the reverse order of removal. Make sure that there is no air leaking out of the blower unit.
6. If the maintenance minder system required you to replace the dust and pollen filter, reset the maintenance minder system (see «RESETTING THE MAINTENANCE INFORMATION DISPLAY»(ref-360264-S42202347502010042800000) ), this procedure is complete. If the maintenance minder system did not require to replace the dust and pollen filter, go to step 6 and reset the dust and pollen filter life with the HDS.
7. Turn the ignition switch to LOCK (0).
8. Connect the HDS to the data link connector (DLC) located under the driver's side of the dashboard (see «GENERAL TROUBLESHOOTING INFORMATION»(ref-360275-S37443495512010042800000) ).
9. Turn the ignition switch to ON (II).
10. Make sure the HDS communicates with the vehicle and the climate control unit. If it doesn't, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-360284-S14481644492010042800000) ).
11. Select BODY ELECTRICAL with the HDS.
12. Select ADJUSTMENT in GAUGE MENU with the HDS.
13. Select SERVICE REMINDER in the EU MAINTENANCE MINDER with the HDS.
14. Select SERVICE REMINDER ITEM 2 with the HDS.

Scheme 99

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Scheme 103

1. Remove the passenger's dashboard undercover (see «PASSENGER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360309-S04468894372010042800000) ) and the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360309-S41537271882010042800000) ).
2. Cut the plastic cross brace (A) in the glove box opening with diagonal cutters in the area (B), and discard it.
3. Remove the bolts and the glove box frame (A).
4. Disconnect the connectors (A) from the A/C wire harness and the mode control motor and air mix control motor.
5. Remove the self-tapping screws and the passenger's heater duct (A).
6. Remove the self-tapping screws, the mounting nuts, and the blower unit (A).
7. Install the unit in the reverse order of removal. Make sure that there is no air leakage.

Blower Unit Component Replacement

Note these items when overhauling the blower unit

Scheme 104

1. The recirculation control motor (A), blower motor (B), and the dust and pollen filter (C) can be replaced without removing the blower unit.
2. Before reassembly, make sure that the recirculation control linkage and door move smoothly without binding.
3. After reassembly, make sure the recirculation control motor runs smoothly (see «MODE CONTROL MOTOR REPLACEMENT»(ref-360275-S07482974202010042800000) ).

Scheme 105

1. Do steps 1 to 8 of the Evaporator Core Replacement (see «EVAPORATOR CORE REPLACEMENT»(ref-360275-S14282158132010042800000) ).
2. Remove the bolts, O-rings (A), and the expansion valve (B) from the pipe (C).
3. Install the expansion valve in the reverse order of removal, and note these items: Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Make sure that there is no air leakage. Charge the system (see «SYSTEM CHARGING»(ref-360275-S23440977812010042800000) ).

Scheme 106

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Scheme 113

1. Recover the refrigerant with a recovery/recycling/charging station (see «RECEIVER/DRYER DESICCANT REPLACEMENT»(ref-360275-S27565743102010042800000) ).
2. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
3. Remove the bolts from the A/C line clamp (A).
4. Remove the bolt, then disconnect the A/C line (B) from the evaporator core and remove the O-rings (C).
5. Remove the blower unit (see «BLOWER UNIT REMOVAL/INSTALLATION»(ref-360275-S34365163302010042800000) ).
6. Remove the mode control motor (see «MODE CONTROL MOTOR REPLACEMENT»(ref-360275-S07482974202010042800000) ).
7. Disconnect the connectors (A) from the evaporator temperature sensor and the power transistor, then remove the connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal.
8. Remove the self-tapping screw (A) and the cover (B).
9. Remove the bolts and the expansion valve from the evaporator core assembly without bending the lines.
10. Carefully pull out the evaporator core assembly (A), then remove the plate (B).
11. Pull out the evaporator temperature sensor (A) from the evaporator core.
12. Install the evaporator temperature sensor in the evaporator core, and note these items: When the evaporator temperature sensor (A) is installed into the new evaporator core, set the sensor into the factory-preset position (B, C). When the evaporator temperature sensor is reinstalled into the original evaporator core, set the sensor into the new position (D, E) because the fin may be deformed by the previous installation. Installing into the factory-preset position Installing into the new position
13. Install the core in the reverse order of removal and note these items: If you're installing a new evaporator core, add refrigerant oil (SP-10) (see «A/C SERVICE TIPS AND PRECAUTIONS»(ref-360275-S36564926332010042800000) ). Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Make sure that there is no air leakage. Charge the system (see «SYSTEM CHARGING»(ref-360275-S23440977812010042800000) ).

Heater Unit/Core Replacement

SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ), and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before doing repairs or service.

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Scheme 118

1. Do the 12 volt battery terminal disconnection procedure, (see «12 VOLT BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360280-S00079896582010042800000) )
2. Disconnect the A/C line from the evaporator core (see «EVAPORATOR CORE REPLACEMENT»(ref-360275-S14282158132010042800000) ).
3. Drain the engine coolant from the radiator (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).
4. From the inlet heater hose, remove the clip (A). Slide the hose clamps (B) back, then disconnect the inlet heater hose (C) and the outlet heater hose (D) from the heater unit. Note the layout of the hoses. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.
5. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines or the brake lines, etc.
6. Remove the dashboard (see «DASHBOARD/STEERING HANGER BEAM REMOVAL/INSTALLATION»(ref-360309-S36561466382010042800000) ).
7. Disconnect these connectors (A): The mode control motor, the power transistor, the evaporator temperature sensor, and the air mix control motor.
8. Remove the duct (A) and the drain hose (B). Remove the mounting nuts and the blower-heater unit (C).
9. Remove the self-tapping screws and the heater core cover (A), the cap (B), and the grommet (C), and carefully pull out the heater core (D).
10. Install the heater core and the evaporator core in the reverse order of removal.
11. Install the heater unit in the reverse order of removal, and note these items: Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Refill the cooling system with engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ). Make sure that there is no coolant leakage. Make sure that there is no air leakage. Refer to the evaporator core replacement (see «EVAPORATOR CORE REPLACEMENT»(ref-360275-S14282158132010042800000) ).
12. Do the 12 volt battery terminal reconnection procedure, (see «12 VOLT BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360280-S00079896582010042800000) )

Scheme 119

1. Remove the passenger's dashboard undercover (see «PASSENGER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360309-S04468894372010042800000) ) and the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360309-S41537271882010042800000) ).
2. Disconnect the 7P connector (A) from the air mix control motor (B). Remove the self-tapping screws and the air mix control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 120

1. Remove the passenger's dashboard undercover (see «PASSENGER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360309-S04468894372010042800000) ) and the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360309-S41537271882010042800000) ).
2. Disconnect the 7P connector (A) from the mode control motor (B). Remove the self-tapping screws and the mode control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 121

1. Open the glove box. While holding the glove box, release the glove box stops on each side from the dashboard by pushing them in, then lower the glove box (see step 1).
2. Disconnect the 7P connector (A) from the recirculation control motor (B). Remove the self-tapping screws and the recirculation control motor from the blower unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 122

1. Remove the instrument panel (see «INSTRUMENT PANEL REMOVAL/INSTALLATION»(ref-360309-S08420322372010042800000) ).
2. Remove the humidity/in-car temperature sensor trim (D) (see «HUMIDITY/IN-CAR TEMPERATURE SENSOR TRIM REMOVAL/INSTALLATION»(ref-360309-S34281827682010042800000) ).
3. Remove the aspirator air hose (A), and disconnect the connector (B).
4. Remove the self-tapping screw and the humidity/in-car temperature sensor (C) from the humidity/in-car temperature sensor trim (D).
5. Install the sensor in the reverse order of removal. Be sure to connect the aspirator air hose securely.

Scheme 123

Scheme 124

1. Remove the front grille cover (see «FRONT GRILLE COVER REPLACEMENT»(ref-360327-S00079186722010042800000) ).
2. Remove the outside air temperature sensor clip (A) from front bumper beam.
3. Disconnect the 2P connector (A) from the outside air temperature sensor.
4. Lift the tab (B) to release the lock, then remove the outside air temperature sensor (C) from the clip.
5. Install the sensor in the reverse order of removal.

Scheme 125

1. Remove the sunlight sensor (A) from the dashboard, then disconnect the connector (B). Be careful not to damage the sensor and the dashboard.
2. Install the sensor in the reverse order of removal.

Climate Control Unit Knob Replacement

Note. Do not work in a dusty or dirty place. Do not work with dusty hands. Discharge static electricity from your body before and during the work. Do not touch the circuit board(s) with your bare hands.

Scheme 126

1. Remove the climate control unit (see «CLIMATE CONTROL UNIT REMOVAL/INSTALLATION»(ref-360275-S07026615932010042800000) ).
2. Remove the knob (A).
3. Install the knob in the reverse order of removal. After installation, operate the various functions to see whether it works properly.
4. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360275-S09008583382010042800000) ).

Climate Control Unit Knob Dial Replacement

Note. Do not work in a dusty or dirty place. Do not work with dusty hands. Discharge static electricity from your body before and during the work. Do not touch the circuit board(s) with your bare hands.

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Scheme 129

1. Remove the climate control unit (see «CLIMATE CONTROL UNIT REMOVAL/INSTALLATION»(ref-360275-S07026615932010042800000) ).
2. Remove the self-tapping screws, and open the cover.
3. Remove the self-tapping screws (A).
4. Pull out knob dial (A).
5. Install the knob dial in the reverse order of removal. After installation, operate the various functions to see whether it works properly. NOTE: Push the knob dial into appropriate position until it clicks.
6. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360275-S09008583382010042800000) ).

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Scheme 132

1. Remove the instrument panel (A) (see «INSTRUMENT PANEL REMOVAL/INSTALLATION»(ref-360309-S08420322372010042800000) ).
2. Disconnect the connector (B) and the climate control unit.
3. Remove the self-tapping screws from the climate control unit.
4. Remove the ring cover (A), and detach the climate control unit (B) from the instrument panel (C).
5. Install the climate control unit in the reverse order of removal. After installation, operate the various functions to see whether it works properly.
6. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360275-S09008583382010042800000) ).